铝活塞盐芯模具设计与压制工艺研究

:20090219;:20100322:(1972),,..Email:[e-mail].31No.5May2010FOUNDRYTECHNOLOGY张屹林,付琳霞,邢小兵(,256602):铝活塞采用内冷油腔结构设计,可以降低其本体工作温度,保障活塞和活塞环工作时的可靠性内冷油腔主要采用氯化钠压制盐芯并铸入活塞毛坯中的方法形成通过试验考察了不同压力下盐芯的紧实率密度和强度的对应关系,给出了盐芯模具型腔设计的通用标准和压制工艺规范经推广验证,试验结论作为工艺规范已成功用于其他产品的批量生产,效果良好:铝活塞;盐芯;挤压模具;压制工艺:TG242.7:A:10008365(2010)05055704ResearchonExtrudingTechnologyandDiesDesignofSaltCoreZHANGYilin,FULinxia,XINGXiaobing(ShandongBinzhouBohaiPistonCo.,Ltd.,Binzhou256602,China)Abstract:Alalloypistondesignedwithinnercoolingchannelstructurecanreduceitsoperatingtemperature,andensuretheworkingreliabilityofpistonandpistonring.Atpresent,innercoolingchannelwaschieflyshapedbysaltcorewhichwasmadefromsodiumchloridebyextrudingmanufacturemethodandcastintopistonsubsequently.Thispaperresearchedthesaltcorescompactedratedensityandintensityunderdifferentpressuresbyexperiment.Theresultsgaveoutgeneralstandardofextrudingdiesdesignofsaltcoreandextrudingtechnology.Ithadbeenprovedsuccessfullybeingasthetechnologystandardandusinginbatchproductionofmakingothertypeofproductswithgoodeffect.Keywords:Alalloypiston;Saltcore;Extrudingdies;Extrudingtechnology,250,,,,[1],25kW/L14~21MPa,,,[2],,,[3,4],NaCl810,;2.15g/cm3,;NaCl,035.6g/100g,NaCl,,,[5],11.1试验材料GB54612000!∀,0.15~0.85mm,1100,,,,[3],1,,#557#FOUNDRYTECHNOLOGYVol.31No.5May20101Tab.1Graindistributionofmostexcellentgradesalt3030~4040~5050~6060~8080~100100~120120wb(%)111291327154-1Fig.1Morphologyofsaltgrain1.2试验模具,,R,,,110mm,22Fig.2Sketchofsaltcoremouldstructure1.3试验方法YB32100,100t2130mm2,h1()22.838cm3,1mm2.204cm3,:∃∃∃∃∃∃∃h2h2;,(48g),,,,,;;;;,;22.1试验结果2MPa11.5MPa,,,251000cm31146g,48g41.9cm32Tab.2Compactingrateanddensityofsaltcoreroughcast/MPa/MPa/mm/cm3(%)/(g/cm3)2.03616.6032.9821.31.462.54514.4628.2632.61.703.05414.0027.2535.01.763.56213.8026.8136.01.794.07113.7626.7236.21.804.58013.7426.6736.31.805.08913.7026.5836.61.815.59813.6026.3637.11.826.010713.2025.4839.21.886.511613.1025.2639.71.907.012512.8024.6041.31.957.513412.7424.4741.61.968.014312.7224.4241.71.978.515212.7224.4241.71.979.016112.7024.3841.81.979.516912.7024.3841.81.9710.017812.6824.3441.91.9710.518712.6424.2542.11.9811.019612.5424.0342.72.0011.520512.5023.9442.92.01#558#!∀05/2010::=(V0-V1)/V0%100%(1)V0&&&;V1&&&333Fig.3Relationbetweencompactingrateandpressureonperprojectiveareaofsaltcore344Fig.4Relationbetweendensityandpressureonperprojectiveareaofsaltcore2.2盐芯强度7.0~10.5MPa,,20,8,55Fig.5Mimeticprobabilitydistributionofintensityofsaltcoreunderdifferentsystempressure7.0~9.5MPa,=0.05,,3,1,1,,F,FF1(f,f)=F0.95(5,114),=0.05,[5]FF0.95(5,114)=2.183Tab.3VarianceanalysistableoftensilebrokenforceofsaltcorefF9.251.80.161306.811411.51316.01193,7.0~9.5MPa,,,2.3试验数据分析234,,,,,,,125~190MPa41%~43%,,,,(),,,,,6,,,,,,,7,,#559#FOUNDRYTECHNOLOGYVol.31No.5May20106143MPaFig.6Sectionmorphologyofsaltcoreunder143MPapressure7205MPaFig.7Sectionmorphologyofsaltcoreunder205MPapressureV0=Vy+Vx(2)=(V0-Vy)/V0%100%(3)Vx=/(1-)%Vy(4)41%~43%(4),Vx=(69.5%~75.4%)VyV0&&&;Vy&&&;Vx&&&;&&&Vx75%Vy,,Vx,80%Vy,,41.1cm3,47.1g,5,,,,,7.0~9.5MPa,;,125~160MPa,;∋1MPa4,125~190MPa1.96~1.98g/cm3,1.97g/cm3,45g,0.5mm2.2g,47.2g125~190MPa0.7~0.8mm,48g3(1)80%,,(2),125~160MPa,,1.96~1.98g/cm3(3),,[1],.[J].,1997,20(4):5355.[2],,.[J].,2004,(9):5456.[3],.[M].:,1999.[4],,,.[J].,1998,19(2):3940.[5]!.[M].:,1963.!∀QQ!∀QQ:1425015247,:,#560#